Use Of 6V3025 Battery Cable Repair Kit{0613, 1400} Caterpillar


Use Of 6V3025 Battery Cable Repair Kit{0613, 1400}

Usage:

All Caterpillar Machines, Generator Installations And Truck Starter Cable Fabrication
Dimensions in mm (inches)

6V3025 Battery Cable Repair Kit has the necessary tools for repair of heavy electrical cable in the wire size range of 8 to 4/0 AWG. Use the instructions that follow for the correct use and maintenance of the repair kit.

Description Of 6V3025 Battery Cable Repair Kit


1. Box Assembly 2. Crimping Tool 3. Cable Cutter

Adjustment Of 6V3021 Crimping Tool

(1) Open the crimping tool handles. Look on die setting chart (1) and make a selection of die letters for the wire size to be used. Depress (push down) pins (2) and turn dies (3) into crimping position for the wire size desired. The die letters (4) must be the same as shown on the die chart for the wire size to be used, such as dies J and H for No. 4 wire. Release the pins.


NOTICE

To prevent damage to the tool, make sure the pins are in position fully and can be seen at locations (5). Put the dies in position E-A for storage of the tool.


Preparation Of Wire

(2) Cut the wire with 6V3022 Cable Cutter. Strip (remove insulation from) the wires to the dimensions shown. Make a selection of the correct size terminal or splice for the wire size to be used. Wire sizes may be shown on some terminals and splices. To find the correct terminal or splices, look at the CMA range chart shown. The total CMA of the wire to be used must be the same as the CMA range of the terminal or splice. Do not use wires with nicks (marks) or that do not have the correct number of strands.

Crimping Procedure

(1) Open the handles of the crimping tool and put the terminal or splice wire barrel in position in the dies for the type of crimp to be used (single or dual). Close the handles until the terminal or splice is held tight against the flats of the dies without any deformation (change in shape) to the wire barrel. For best results, put wire barrel seam (1) in position against one of the die flats as shown. Install stripped wire (2) into the terminal or splice as shown for the type of crimp to be used. Close the handles of the tool until they lock (close over center). Open the handles and remove the crimped item.

NOTE: Make sure the correct selection of dies has been made for the wire size to be used.

Types Of Crimps

(1) The single crimp procedure is used on wire sizes 8, 6 and 4. Put the center of the wire barrel of the terminal or parallel splice in the dies as shown. Install the stripped wire into the terminal or parallel splice until the end of the wire conductor is at least even with or extended a little beyond the end of the barrel. Make the crimp. For butt splices, put the center of one half of the wire barrel in the dies as shown. Install the stripped wire into the wire barrel until the end of the wire conductor stops against the butt splice wire stop (1). Make the crimp. For the other half of the butt splice, use the same procedure. See pages 13 and 14 for Inspection of Crimps.

NOTE: The dual crimp procedure is used for wire sizes 2 through 4/0. Be sure the crimps do not overlap (connect with) each other or go off either end of the wire barrel. See pages 15 and 16 for Inspection of Crimps.

Terminal

(2) To make the first crimp on a terminal, put the end of the wire barrel in position (2) in the dies as shown. Install the wire as in step 1 and make the crimp. Put the terminal in position (3) as shown to make the second crimp on the terminal. Make the second crimp.

Butt Splice

(3) To make the first crimp on a butt splice, put the splice in position (4) as shown and install the stripped wire. See Step 1. Make the first crimp. Move the splice into position (5) for the second crimp. Make the crimp. Slide a heat shrink tube over the splice and move it along the wire to a position clear of the splice. Put the splice in position (6) as shown. Install the other stripped wire and make the third crimp. Put the splice in position (7) and make the fourth crimp. Slide the heat shrink tube over the center of the splice. Heat the tube with a torch or a heat gun until it seals around the butt splice.

Parallel Splice

(4) To make the first crimp on a parallel splice, put the splice in position (8) as shown. Install the stripped wires as in Step 1 and make the crimp. Put the splice in position (9) and make the second crimp.

Installation Of Battery Terminals

NOTE: The adjustment of the dies and the crimping procedure are the same as shown on pages 3 and 5, respectively. Cut the wire with 6V3022 Cable Cutter. The wire stripping length and the tool die settings for the wire size to be used are shown on the following chart. Be sure the crimps do not overlap (connect with) each other or go off either end of the wire barrel. Heat shrink tubes can be used, if necessary; see page 8, Step 3. See pages 17 and 18 for Inspection of Crimps.

(1) Make a selection from the chart of the correct tool die setting for the wire size to be used. The selection of wire strip length is according to the type of battery terminal used. For straight terminals (1), the wire strip length is 20.6 (0.81") to 21.4 (0.84"). For left and right hand flag terminals (2), the length is 18.3 (0.72") to 19.1 (0.75"). For standard (3) and long barrel (4) flag terminals, the wire strip length is dimension (A) as shown, plus 0.79 (0.031").

(2) Put the straight battery terminal (1) in position (B) as shown for the first crimp. Install the stripped wire in the terminal until it bottoms (stops). Make the crimp. Move the terminal to the second position (C). Make the crimp.

(3) Put the flag standard barrel terminal (3) in position (D) as shown. Install the stripped wire through the wire barrel until the end of the conductor is even with or 0.79 (0.031") beyond the end of the terminal wire barrel. Make the crimp. Move the terminal to the second position (E). Make the crimp.

(4) Put the flag long barrel terminal (4) in position (F) as shown. Install the stripped wire into the barrel to the insulation. Make the crimp. Move the terminal to the second position (G). Make the crimp. Move the terminal to the third position (H). Install the stripped wire. Make the crimp. Move the terminal to the fourth position (J). Make the crimp. For the flag right and left hand terminals (not shown), install the stripped wire in the terminals until it stops. Install the flag right hand terminal by the same method used for the flag long barrel terminal, positions (F) and (G). Install the flag left hand terminal by the same method used for positions (H) and (J).

Inspection Of Crimps

NOTE: Use only the terminal and splice crimp conditions shown that are Acceptable. Correct use of the tooling and procedures can prevent the crimp conditions shown that are Not Acceptable.

(1) Single Crimps - Acceptable
a. Crimp (1) is in the center of the wire barrel. The crimp may be slightly off the center, but not off the end of the barrel.
b. The terminal or splice (2) is correct for the CMA of the wire size used.
c. Insulation (3) is not in the wire barrel.
d. The wire shows through inspection hole (4) of the butt splice.
e. Stripped wire ends (5) are even with or slightly beyond the end of the wire barrel.

(2) Single Crimps - Not Acceptable
a. Crimp (1) is off the end of the barrel of the terminal or splice.
b. The terminal or splice (2) is not correct for the wire used.
c. Insulation (3) has been put into the wire barrel. Check for wrong wire strip length.
d. The wire does not show through inspection hole (4) of the butt splice.
e. The stripped wire ends (5) are not even with or slightly beyond the end of the barrel.
f. Strands (6) are nicked (marked) or there are not enough complete strands.

(3) Dual crimps - Acceptable
a. Crimps (1) are in the correct position. They do not make contact with each other or are not off the end of the barrel.
b. The terminal or splice (2) is correct for the CMA of the wire used.
c. Insulation (3) is not in the wire barrel.
d. The wire shows through inspection hole (4) of the butt splice.
e. The stripped wire ends (5) are even with or slightly beyond the end of the barrel.

(4) Dual Crimps - Not Acceptable
a. Crimp (1) is off the end of the barrel or makes contact with the other crimp.
b. The terminal or splice (2) is not correct for the CMA of the wire used.
c. Insulation (3) has been put in the wire barrel. Check for wrong wire strip length.
d. The wire does not show through inspection hole (4) of the butt splice.
e. The stripped wire ends (5) are not even with or slightly beyond the end of the barrel.
f. Strands (6) are nicked (marked) or there are not enough complete strands.

(5) Battery Terminal Crimps - Acceptable
a. Crimps (1) are in the correct position. They do not make contact with each other and are not off the end of the barrel.
b. The diameter of stripped wire (2) is correct for the wire diameter range of the battery terminal.
c. Wire (2) is in position in the wire barrel correctly.
d. The wire is not nicked (marked) and has the correct number of strands (3).

(6) Battery Terminal Crimps - Not Acceptable
a. Crimp (1) is off the end of the barrel or makes contact with the other crimp.
b. The diameter of stripped wire (2) is not correct for the wire diameter range of the terminal.
c. Wire (2) is not in the correct position in the wire barrel. Check for wrong wire strip length.
d. The wire is nicked (marked) or does not have the correct number of complete strands (3).

Inspection And Maintenance Of 6V3021 Crimping Tool

(1) Operate the tool and inspect for loose, bent or worn parts or parts that are gone. Inspect the die surfaces for chipped (1) or pitted (2) conditions.

(2) Use a good grade of S.A.E. No. 20 motor oil for lubrication of all pins, pivot points and bearing surfaces. The lubrication of the tool should be as follows: daily use (production) - daily lubrication; daily use (now and then) - weekly lubrication; weekly use - monthly lubrication. Remove excess (extra) oil from the tool, particularly from the die crimp surfaces. Oil from the dies that gets on certain terminations may change the electrical characteristics of an application.

(3) To be sure of correct compensation for normal die wear, check the handle adjustment to see if dies are correctly engaged.

a. Open handles (3) all the way.

b. Put dies E and A into crimp position.

c. Close the handles until the dies are engaged, but not under pressure.

d. Measure distance (B) between the handles as shown.

1) Adjustment is too tight if measurement (B) is more than 41.3 (1.63").
2) Adjustment is too loose if measurement (B) is less than 34.9 (1.38").

e. If measurement (B) is more than 41.3 (1.63"), do the steps that follow:

1) Turn both adjustment (ADJ) screws (4) counterclockwise approximately 1/2 to 3/4 turn.

2) Move both lock (LOCK) screws (5) counterclockwise.

3) Open and close the handles several times.

4) Tighten lock screws (5).

5) Close the handles as in Step (C). Check measurement (B) between handles and again follow the adjustment procedure, if necessary.

f. If measurement (B) is less than 34.9 (1.38"), do the steps that follow:

1) Turn lock screws (5) counterclockwise approximately 1/2 to 3/4 turn.

2) Turn adjustment screws (4) clockwise approximately 1/2 to 3/4 turn.

3) Open and close the handles several times.

4) Tighten lock screws (5).

5) Close the handles as in Step (C). Check measurement (B) between the handles and again follow the adjustment procedure, if necessary.

(4) The crimp height measurements should be made at regular intervals to check if the tool has kept correct die crimping dimensions. Use the steps that follow to make the test.

a. Check the handle adjustment in Step 3.

b. Make a correct crimp on a terminal or splice.

c. Use a cone point micrometer and make two crimp height measurements as shown. Do not permit the cone point to come in contact with the terminal or splice seam.

d. Add the two measurements (C) and (D) together to get the crimp height dimension.

e. If the crimp height dimension is within the range shown, then the dies are correct and the tool works correctly. If not, check the tool for parts that are worn or have defects.

(5) To remove a die from the tool, remove nut (5). Remove capscrew (6) and spring (7) from pin assembly (8). The pin assembly has threads to hold the capscrew. Remove pin assembly (8) and die (9) from the tool.


NOTICE

Put identification on the dies for correct installation. Install replacement dies as a set.


(6) To install a die, put die (9) in position with the letters on the die toward the front of the tool. Put pin assembly (8) in position and install spring (7) and capscrew (6). Install nut (5).

Replacement parts (die sets) or repairs are available through an AMP service center or from:

AMP SPECIAL INDUSTRIES
Attn: National Accounts
Valley Forge, PA 19482 U.S.A.
Phone: (215) 647-1000, ext. 527

Caterpillar Information System:

Installation Of 3N6351, 3N8285, 3N9095 And 7T5287 Modulating Valve Groups In Marine Transmissions{3300} Installation Of 3N6351, 3N8285, 3N9095 And 7T5287 Modulating Valve Groups In Marine Transmissions{3300}
Installation Of 5N7375, 5N7376 And 5N7377 Enclosure Groups For Package Generator Sets{7002} Installation Of 5N7375, 5N7376 And 5N7377 Enclosure Groups For Package Generator Sets{7002}
Installation Of 4W9528 Enclosure Group For Package Generator Sets{7002} Installation Of 4W9528 Enclosure Group For Package Generator Sets{7002}
Use Of 6V200 Hydraulic Wrench{0614, 0623} Use Of 6V200 Hydraulic Wrench{0614, 0623}
Service Information And Instructions For Use of 5P8585 Leak Detector{0651, 7320} Service Information And Instructions For Use of 5P8585 Leak Detector{0651, 7320}
installation of 9n6275 cylinder sleeve{1222} installation of 9n6275 cylinder sleeve{1222}
Installation Of 2N7003 Soot Filter{1054} Installation Of 2N7003 Soot Filter{1054}
Procedure To Test And Adjust 5P4210 Cab Tilt Cylinder Arrangement{0623} Procedure To Test And Adjust 5P4210 Cab Tilt Cylinder Arrangement{0623}
Use Of 1P4000 Line Boring Tool Group{0672, 1201, 1203} Use Of 1P4000 Line Boring Tool Group{0672, 1201, 1203}
Installation Of Crankshaft Seals And Wear Sleeves{1203} Installation Of Crankshaft Seals And Wear Sleeves{1203}
Installation Of 8N6938 Or 8N6939 Inserts{1217} Installation Of 8N6938 Or 8N6939 Inserts{1217}
Installation Of 7N7783 Sleeve And 8N6579 Spring Or 8N7526 Governor Group{1264} Installation Of 7N7783 Sleeve And 8N6579 Spring Or 8N7526 Governor Group{1264}
Use Of 1P3550 Wiring Harness Tester Group (24 Volt){0709, 3168} Use Of 1P3550 Wiring Harness Tester Group (24 Volt){0709, 3168}
Installation Of 5N7499 And 5N7500 Front Power Take-Off Groups{3107} Installation Of 5N7499 And 5N7500 Front Power Take-Off Groups{3107}
Installation Of 8N6287 Fuel Priming Knob Kit{1258} Installation Of 8N6287 Fuel Priming Knob Kit{1258}
Installing Heli-Coil Inserts In Caterpillar Cylinder Heads{1117} Installing Heli-Coil Inserts In Caterpillar Cylinder Heads{1117}
Pressure Lubrication Procedure For Remanufactured Engines And Short Blocks{1000, 1201} Pressure Lubrication Procedure For Remanufactured Engines And Short Blocks{1000, 1201}
Installation Of 5N5880 Remote Shut-Off Group And 5N6336 Gauge Group{7400, 7418} Installation Of 5N5880 Remote Shut-Off Group And 5N6336 Gauge Group{7400, 7418}
Installation Of Replacement Drive Sleeve For Marine Transmission Oil Pump{3310} Installation Of Replacement Drive Sleeve For Marine Transmission Oil Pump{3310}
Use Of 8T0455 Cylinder Liner Projection Indicator Group{0760, 1216} Use Of 8T0455 Cylinder Liner Projection Indicator Group{0760, 1216}
Use Of FT1525 Alignment Pin, FT1526 Salvage Fixture And FT1698 Bearing Installation Tool For Reconditioning Of 3208 Governor Housings{1265, 1264} Use Of FT1525 Alignment Pin, FT1526 Salvage Fixture And FT1698 Bearing Installation Tool For Reconditioning Of 3208 Governor Housings{1265, 1264}
Installation Of 8N6414 Ether Starting Aid Group{1456} Installation Of 8N6414 Ether Starting Aid Group{1456}
2W715 Turbocharger Cartridge Repair Kit{1053} 2W715 Turbocharger Cartridge Repair Kit{1053}
Installation Of Replacement Parts For 3N7722, 8N2744, 1W1872, 1W1873, 1W1881 and 1W1882 Engine Oil Pump Groups{1304} Installation Of Replacement Parts For 3N7722, 8N2744, 1W1872, 1W1873, 1W1881 and 1W1882 Engine Oil Pump Groups{1304}
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.